Modular condenser fan assembly

ABSTRACT

A modular condenser fan/motor assembly for use in a transport refrigeration system includes a support frame, a fan shroud panel, a fan/motor assembly and a support bracket. A fan and motor assembly for use in a transport refrigeration unit includes a fan impeller disposed about an inside/out motor, whereby the fan impeller rotates with at least a portion of an outer casing of the motor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority from U.S. Provisional Patent Application Ser. No. 61/031,158, filed Feb. 25, 2008, and entitled: Modular Condenser Fan Assembly.

This application is related to the following application subject to the common assignee of this application and filed with the United States patent and Trademark Office on the same date as this application: U.S. patent application Ser. No. (Attorney Docket No. 210_(—)1151 NP), entitled “Dual Condenser Fans With Center Partition”.

FIELD OF THE INVENTION

This invention relates generally to transport refrigeration systems and, more particularly, to an assembly of a condenser fan, fan motor, shroud and frame assembled into a drop-in module.

Transport refrigeration systems are commonly employed in connection with refrigerated transport trailers used in shipping perishable goods. The transport trailer is adapted to be connected to and towed by a truck tractor. The transport refrigeration system includes a refrigerant unit, an electric generator assembly and an engine for driving the electric generator, all supported on a framework structural support configured to be mounted to the front wall of the trailer.

In transport refrigeration systems, the refrigeration unit includes a condenser heat exchanger through which refrigerant is passed in heat exchange relationship with ambient air as a cooling medium for condensing refrigerant from a vapor phase into a liquid phase. Generally one condenser fan is provided, and sometimes two condenser fans are disposed in a side-by-side arrangement, condenser fans are provided to draw the ambient air through the condenser heat exchanger.

Heretobefore, condenser fans for transport refrigeration units have either been driven by belts and pulleys, or by complex arrangements of fan, motor, fan shroud and support structure. When service or component replacement is necessary, the components have to be serviced in place or removed individually for service. Thus, performing service on the various condenser fan components is often difficult and time-consuming due to access limitations. Reassembly, as well, may often be complicated and time-consuming due to necessary adjustments, e.g. belts, and the proper alignment of the reassembled components.

U.S. Pat. No. 5,660,149 discloses a cooling fan module that is included as one component of a total cooling assembly that is adapted for drop-into installation in the engine compartment of an internal combustion engine-powered automotive vehicle. The cooling fan module includes a panel structure in which a cooling fan and fan motor assembly is mounted and to which an electric controls module and an electric cooling pump and motor assembly are also mounted.

SUMMARY OF THE INVENTION

In an aspect of the invention, a modular assembly of a condenser fan, fan motor, fan shroud panel, fan support bracket and structural support frame is provided. The modular assembly facilitates removal and reinstallation of the condenser fan and related components for servicing.

In an embodiment, the modular condenser fan assembly includes a support frame having a first side and a second side, a fan shroud panel disposed on the first side of the support frame, a support bracket disposed on the second side of the support frame, and a fan/motor assembly disposed between the fan shroud panel and the support bracket.

In an embodiment, the modular condenser fan assembly includes a support frame having a first side and a second side, a fan shroud panel removably mounted to the support frame on the first side of the support frame, a support bracket removably mounted to the support frame on the second side of the support frame, and a fan/motor assembly disposed between the fan shroud panel and the support bracket.

In an aspect of the invention, a fan and motor assembly for use in a transport refrigeration unit includes a fan impeller disposed about an inside/out motor, whereby the fan impeller rotates with at least a portion of an outer casing of the motor. In an embodiment of the fan and motor assembly, the outer casing of the motor has a rotatable portion and the fan impeller rotates with the rotatable portion of the outer casing of the motor. The fan impeller may include an inner shroud, an outer shroud disposed in spaced relationship and circumscribing the inner shroud, and a plurality of blades extending between the inner shroud and the outer shroud, with the inner shroud being disposed about and rotatable with the rotatable portion of the outer casing of the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of an exemplary embodiment of the modular condenser fan assembly of the present invention;

FIG. 2 is a front elevation view of the assembled modular condenser fan assembly of FIG. 1;

FIG. 3 is a rear elevation view of the assembled modular condenser fan assembly of FIG. 1;

FIG. 4 is a perspective view of another exemplary embodiment of an assembled modular condenser fan assembly of the present invention;

FIG. 5 is a side elevation view, partly in section, of an assembled modular condenser fan assembly installed in a transport refrigeration system;

FIG. 6 is a perspective view, from the rear, of a partially assembled transport refrigeration system showing a pair of modular condenser fan assemblies installed therein; and

FIG. 7 a perspective view illustrating a transport refrigeration system mounted to front wall of the trailer of a truck and trailer unit.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1-3, in particular, the modular condenser fan assembly, designated generally at 10, includes a condenser fan/motor assembly 20, a support bracket 34, a fan shroud panel 40 and a support frame 50. The fan shroud panel 40 is disposed on a first side of the support frame 50 and the support bracket 34 is disposed on a second side of the support frame 50. The fan/motor assembly 20 is disposed between the fan shroud panel 40 and the support bracket 34.

The condenser fan/motor assembly 20 includes an impeller 22 that is disposed about an associated fan motor 30, which may be a so-called “inside/out” type motor as illustrated in the depicted embodiments. In an “inside/out” motor, the shaft of the motor is the motor stator and the outer casing, or a portion of the outer casing, is the motor rotor. The impeller 22 has a plurality of blades and an outer shroud 24 and an inner shroud 26. The inner shroud 26 is disposed about a central portion 30A of the outer casing of the motor 30 so as to rotate with the central portion 30A of the outer casing, which as noted before forms the motor rotor. The motor 30 is supplied with electrical power through a cord 65 which connects to a power supply box 80, as seen in FIG. 3. The power supply box 80 receives electrical power from an onboard electric generator 200 powered by a diesel engine 100, shown in FIG. 6, or from an off-board power supply (not shown) when the diesel engine 100 is not operating.

The spider-like support bracket 34 has a plurality of legs 38 extending outwardly and forwardly from a central member 36 that defines an opening adapted to receive the rearward end 32 of the motor 30 in supporting relationship. A plurality of forwardly extending clips 33 may be provided at spaced intervals about the circumference of the central member 36 for correctly aligning the motor 30. At its distal end, each leg 38 has a foot 39 that has a hole therethrough for receiving a mounting device.

The support frame 50 includes a plurality of structural members 52, such as for example box channel members, welded together or otherwise arranged to form a rectangular frame, and a pair of structural members 54, such as for example box channel members. In the exemplary embodiment, the structural members 54 extending transversely between a first pair of oppositely disposed structural members 52C and parallel to a second pair of oppositely disposed structural members 52A, 52B. Additionally, the support frame 50 includes a pair of mounting lugs 56 by which the modular condenser fan assembly 10 may be mounted to the structural frame of the transport refrigeration unit. In the depicted embodiment, the mounting lugs 56 are mounted to the upper support member 52A of the support frame 50, for example by welding. The support frame 50 may also include an additional pair of support lugs 57 mounted to the lower support member 52B of the support frame, for example by welding.

The fan shroud panel 40 has a vertical and horizontal expanse that corresponds generally with the outer dimensions of the support frame 50 and defines a central opening 45. An annular flange 42 extends outwardly from the rear face of the fan shroud panel 40 circumferentially about the central opening 45. Also, if desired, a gasket may be provided about the perimeter of the fan shroud panel 40. The gasket may be formed of a plurality of gasket strips 43, such as for example neoprene strips, adhesively bonded to the fan shroud panel 40, such as illustrated in FIG. 1.

To assemble the modular condenser fan assembly 10, first, the fan shroud panel 40 is mounted to the support frame 50 with the rear face of the fan shroud panel abutting a first side, i.e. the forward face in the depicted embodiment, of the support frame 50 by means of removable fasteners, such as for example cap screws 44 extending through the panel 40 and secured into nuts 44A mounted to the transversely extending structural members 54 of the frame. Next, the fan/motor assembly 20 is positioned over the central opening 45 in the fan shroud panel with the annular flange 42 fitting within a forward lip 23 extending about the circumference of the outer shroud 24 of the fan/motor assembly 20. With the fan/motor assembly 20 so positioned, the support bracket 34 is positioned on the motor 30 with the rearward end 32 of the motor 30 received within the central opening 35 of the support bracket 34 and secured to the rim 31 of the rearward end of the motor 30 by removable fastening devices, such as cap screws 37. With the support bracket so positioned, the feet 39 of the respective legs 38 of the support bracket 34 abut against a pair of oppositely disposed structural members 52 of the frame 50 on a second side, i.e. the rear face in the depicted embodiment, of the support frame 50 and are secured thereto by removable fastening devices, such as for example cap screws 58, inserted through mounting holes provided in the feet 39 and secured to nuts 58A mounted to the support members 52, thereby mounting the fan/motor assembly 20 the frame 50. It is to be understood that removable fastening devices other than cap screws with mating nuts may be used to mount the fan shroud panel 40 and the support bracket 34 to the support frame 50.

Referring now to FIG. 4, in the exemplary embodiment depicted therein, each of the feet 39 of the legs 38 of the spider-like support bracket 34 abuts against a respective one of a plurality of corner plates 59, rather than against one of the frame members 52 of the support frame 50 as in the exemplary embodiment shown in FIGS. 1-3. Four corner plates 59 are provided, one corner plate extending inwardly from each corner formed at the junction of the structural members 52 and 54. The corner plates 59 are supported from the frame 60, for example by, but not limited to, being welded to one of both of the structural members 52 and 54. In this embodiment, the feet 39 are mounted to the respective corner plates 59 by removable fastening devices, such as for example bolts or screws.

Referring now to FIGS. 5 and 6, the modular condenser fan assembly 10 is positioned within the structural framework 60 of the transport refrigeration system at the forward side thereof aft of the condenser 70 and forward of the evaporator housing 80. In the depicted embodiment, the modular condenser fan assembly 10 is positioned above the diesel powered engine 100 and electric generator 200 driven by the engine such that the ambient air drawn through the condenser 70 and discharging from the condenser fans will flow over the engine and generator to assist in the cooling thereof. To install the modular condenser fan assembly 10 within the framework 60, the modular assembly 10 is simply dropped downwardly into the unit and mounted to a forward structural member of the framework 60. When the modular assembly 10 is dropped into the unit, the lower support lugs 57 engage and slip over a set of lower bolts (not shown) secured to the framework 60. So positioned, the modular assembly 10 is then secured to the framework 60 by inserting and tightening removable fastening devices 66, such as for example bolts or screws, passing through mounting holes provided in the support lugs 56 to be secured to one of the support members forming the framework 60 of the transport refrigeration unit, and then tightening the lower bolts to secure the lower support lugs 57 to the framework 60.

To remove the modular condenser fan assembly for service of any of the components thereof, the service technician merely needs to remove the two fastening devices 66 securing the upper support lugs 56, loosen the bolts securing the lower support lugs 57, disconnect the motor 30 from the electric power supply, and lift the entire modular assembly out of the unit for easy access to any and all of the components of the modular condenser fan assembly. This feature enables easy access to the modular assembly 10 for service and/or replacement of components and also enables replacement of the entire modular assembly 10 with another modular assembly in a very short amount of time.

Referring now also to FIG. 7, there is illustrated a transport refrigeration system 110 mounted to the front wall of a refrigerated trailer 130 pulled by a tractor 120. As is common for transport refrigeration systems, an outer cover 105, itself supported on the structural framework 60, covers the framework 60 and all of the components of the refrigeration unit, including but limited to a compressor (not shown), an evaporator and associated evaporator fan/motor assembly (not shown) disposed within the confines of the evaporator housing 80, the condenser heat exchanger 70 and the condenser fan/motor assemblies 20, as well as the engine 100 and the electric generator 200 driven by the engine 100.

The terminology used herein is for the purpose of description, not limitation. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as basis for teaching one skilled in the art to employ the present invention. While the present invention has been particularly shown and described with reference to the exemplary embodiments as illustrated in the drawing, it will be recognized by those skilled in the art that various modifications may be made without departing from the spirit and scope of the invention. Those skilled in the art will also recognize the equivalents that may be substituted for elements described with reference to the exemplary embodiments disclosed herein without departing from the scope of the present invention.

Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as, but that the disclosure will include all embodiments falling within the scope of the appended claims. 

1. A modular condenser fan assembly for use in a transport refrigeration system, comprising: a support frame having a first side and a second side; a fan shroud panel disposed on the first side of said support frame; a support bracket disposed on the second side of said support frame; and a fan/motor assembly disposed between said fan shroud panel and said support bracket.
 2. A modular condenser fan assembly for use in a transport refrigeration system, comprising: a support frame having a first side and a second side; a fan shroud panel removably mounted to said support frame on the first side of said support frame; a support bracket removably mounted to said support frame on the second side of said support frame; and a fan/motor assembly disposed between said fan shroud panel and said support bracket.
 3. A fan and motor assembly for use in a transport refrigeration unit comprising a fan impeller disposed about an inside/out motor, whereby the fan impeller rotates with at least a portion of an outer casing of the motor.
 4. The fan and motor assembly as recited in claim 3 wherein the outer casing of the motor has a rotatable portion and the fan impeller rotates with the rotatable portion of the outer casing of the motor.
 5. The fan and motor assembly as recited in claim 4 wherein the fan impeller has an inner shroud, an outer shroud disposed in spaced relationship and circumscribing the inner shroud, and a plurality of blades extending between the inner shroud and the outer shroud, the inner shroud being disposed about and rotatable with the rotatable portion of the outer casing of the motor. 